The document presents a design and performance analysis of a refrigeration system utilizing R12 and R134a refrigerants, focusing on their comparative behavior and industry challenges. R12, while efficient and widely used, is being phased out due to its ozone depletion potential, whereas R134a is deemed a viable alternative with zero ODP. The study ultimately recommends transitioning to R134a for various applications due to its environmentally friendly properties and comparable performance metrics.

1. K. Nagalakshmi et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.638-643
RESEARCH ARTICLE
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OPEN ACCESS
The Design and Performance Analysis of Refrigeration System
Using R12 & R134a Refrigerants
K. Nagalakshmi1, G. Marurhiprasad Yadav2
1
. Mechanical engineer at St.Jhons College of Engg &Technology, Yemmiganur-518360, A. P, India.
. Associate professor, Department of Mechanical engineering, St.Jhons College of Engg &Technology,
Yemmiganur-518360, A. P, India.
2
ABSTRACT
The design and performance analysis of refrigeration system using R12 & R134a refrigerants are presented in
this report. The design calculations of the suitable and necessary refrigerator equipment and their results are also
reported here. CFC-12 is the most widely used refrigerant. It serves both in residential and commercial
applications, from small window units to large water chillers, and everything in between. Its particular
combination of efficiency, capacity and pressure has made it a popular choice for equipment designers.
Nevertheless, it does have some ODP, so international law set forth in the Montreal Protocol has put CFC-12 on
a phase out schedule.HFC-134a has been established as a drop-in alternative for CFC-12 in the industry due to
their zero Ozone Depletion Potential (ODP) and similarities in thermodynamic properties and performance.
However, when a system is charged with a HFC-134a compressor oil has to be changed.Not enough research
has been done to cover all aspects of alternative refrigerants applications in the systems. This project intended to
explore behavior of this alternative refrigerants compare to CFC-12 and challenges the industry is facing in
design, operation services and maintenance of these equipments.The purpose of this project is to investigate
behavior of R134a refrigerant. This includes performance and efficiency variations when it replaces R12 in an
existing system as well as changes involved in maintaining the system charged with R134a. This project is
intended to address challenges faced in the real world and some practical issues. Theoretical and experimental
approaches used as a methodology in this work.
Keywords - alternate refrigirents, evaporator, HCFCs, ODP, GWP.
I. INTRODUCTION
Refrigeration is concerned with the
absorption of heat from where it is objectionable plus
its transfer to and rejection at a place where it is
unobjectionable. Regardless of means by which is
heat transfer is accomplished; the problem is one of
applied thermodynamics. In some methods of
refrigeration the working medium that approaches
perfect gases may be applied.A refrigerant is a
compound used in a heat cycle that undergoes a
phase change from a gas to a liquid and back. The
two
main
uses
of
refrigerants
are
refrigerators/freezers and air conditioners. In
broadest sense the word refrigerant is also applied to
such secondary cooling medium as brine solutions,
cooled water. The refrigerants include only those
working mediums, which pass through the cycle or
evaporation, recovery, compression and liquefaction.
ANALYSIS OF VAPOUR COMPRESSION
CYCLE DIAGRAM
The flow diagram T-Ǿ and P-H diagrams of a vapour
compression refrigerating system given below.
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fIg.1
1-2 ISENTROPIC COMPRESSION
Refrigerant
vapour
received
evaporator is compressed isentropically
compressor by external source of energy
from
in a
fig.2
(work in out), pressure and temperature increase.
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2. K. Nagalakshmi et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.638-643
2-3 CONDENSATION
Compressor discharges vapour into the
condenser where it condensed completely i.e. turns
in to liquid. Heat is rejected from the refrigerant to
cooling medium, usually air or water.
3-4 EXPANSION
From condenser liquid refrigerant passes
through the expansion valve where it is throttled
resulting in a drop of temperature and pressure.
However, enthalpy remains constant (throttling
expansion)
4-1 EVAPORATION
Liquid refrigerant at a low temperature
passes into evaporator where it extract heat from the
product to be cooled. Due to absorption of extract
heat liquid refrigerant turns into vapour, and enters in
to the compressor.
COEFFICIENT OF PERFORMANCE
Work input W=H2-H1
Refrigerating effect N=H1-H4
Since, during the process 3-4, enthalpy is constant.
Therefore enthalpy at 4(H4) is equal to enthalpy at
3(H3)
Refrigerating effect N=H1-H3
C.O.P=REF EFFECT /WORK INPUT=H1-H3/H2H1
II. DETAILS OF DESIGN AND
CONSTRUCTION
SELECTION OF COMPRESSOR
Compressor specifications
Motor H.P=1 H.P.
Speed= 640 r.p.m
Cylinder specifications
No of cylinders = 1
Bore diameter = 63.5 mm
Stroke length = 762 mm, Displacement = 4825
cm³
DETAILS OF DESIGN EVAPORATOR
The selected evaporator for the design is
natural convection bare tube, Dry Expansion, Shell
and tube Evaporators.
Heat reaches the Evaporator by all three
methods of heat transfer and conduction and
radiation.
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Inlet temperature of the evaporator coil (T 1) = -1.6°C
Outlet temperature of evaporator coil (T 2) = 3.4°C
Temperature difference between inside and outside
of the evaporator = (3.4)+(1.6) = 5
The overall heat transfer, co-efficient “U” factor
from data tables for copper = 400kcal/m2-hr-°C
Load taken by the evaporator = AU ∆T
i.e. Refrigerating capacity = AU ∆T
Refrigerating capacity = load taken by Evaporator =
1555 = AU ∆T
A = 1555/ U ∆T = 1555/ (400 x 5) = 0.77 m2
Diameter of the coil (D) = 5mm
Then
A = пDL
Length of the coil (L) = A/пD = 0.77/(п x 0.005) =
49.5m2
Length of coil in one turn = 2(40+20)
= 180 cm
Number of turns in the tank = 4950/180
= 27.4 turns, say 28 turns
Provide 10 cm gap between each turn of the coil. The
evaporator coil should be arranged the side of the
tank that will be easy for periodic cleaning.
SELECTION OF CONDENSER
The condenser load can be calculated by the
following equation:
Heat transfer Q=m Cpl (T3-T2)
Load on the condenser = m Cpl (T 3-T4)
Q = heat absorbed in evaporator + heat of
compressor.
Heat absorbed in evaporator = 1555 k cal/h
Heat of compressor = v x 1
= 220 x 3
=640w
= 640 x 0.86
= 550.4 kcal.
Q = 1555 + 550.4 = 2105.4 k cal
Q = UA ∆T
A = 2105.4/ 400 x 22
= 0.239
A = Пdl
d = 5mm
Length of coil (L) = 0.239 / 0.005
= 15.23m
LENGTH IN ONE TURN = (40 + 40) = 80cm
Number of turns required = 15.23 / 0.80
= 19.0389
= 20
DESIGN OF EVAPOURATOR
fig.4
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3. K. Nagalakshmi et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.638-643
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IV. RESULTS & DISCUSSIONS:
Graphs are drawn from the above tabulated
results.
 Coefficient of Performance with Evaporator
Temperature at a constant Condenser
Temperature.
 Compressor exit Temperature with Evaporator
Temperature at a constant Condenser
Temperature.
 Specific Volume at inlet to Compressor with
Evaporator Temperature.
Variation of Coefficient of performance with
evoparator temperature at condensor
temperature of 30 oc




Replace the compressor.
Flush the entire system clean with alcohol and
let it be free for few hours.
Then rinse it with alcohol again and then blew it
clean with DRY AIR (if you don't have a good
air dryer for your compressor (or have no
compressor), get a good compressed air).
Replace all seals on the spring clamp and screwtogether.
Put the required amount of lubricating oil in the
compressor.
Charge with the new R134A refrigerant
CALCULATIONS
Evaporator Temperature (T 1) = -30ºC
Condenser Temperature (T2¹) = 30ºC
From charts,
At -30ºC, Enthalpy (h1) = 338.143 kJ/kg
Entropy (s1) = 1.57507 kJ/ (kg.K)
At 30ºC, Enthalpy (h2¹) = 363.566 kJ/kg
Entropy (s2¹) = 1.54334 kJ/ (kg.K)
Enthalpy (h3) = 228.540 kJ/kg
From the graph,
s1 = s2 and h3 = h4
We know that,
h2 = h2¹ + Cр (T2 – T2¹)
Equation – A
s2 = s2¹ + Cр ln (T2/T2¹)
1.57507 = 1.54334 + 0.7253 * ln (T2/303)
On simplification we get, T2 = 316.5 K
Substituting in Equation – A we have,
h2 = 363.566 + 0.7253 * (316.5 – 303)
= 373.35 kJ/kg
(1)Refrigerating Effect = h1 – h4
= 109.603 kJ/kg
(2)Coefficient
of
Performance
(C.O.P)
=
Refrigerating Effect / Work done by the Compressor
= (h1 – h4)/ (h2 – h1)
= 3.11
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6
5
4
3
2
1
0
R-12
R-134a
-35 -30 -25 -20 -15 -10 -5 0
Temperature in oC
fig.6 Variation of C.O.P with evaporator temp.at
condenser temperature of 30oc
From the Fig.6 It is observed that the
coefficient of performance of the refrigeration
system is increasing almost linearly as the
Evaporator Temperature is increased when the
refrigerant used was R-12. the shape of the graph is
almost similar when the results were plotted using R134a as the refrigerant however it is observed that
the values of coefficient of performance are slightly
higher in case of refrigerants R-12 . But refrigerant
are R-134a may be preferred because of the zero
value of the ozone depletion potential.
Variation of Coefficient of performance
with evoparator temperature at condensor
temperature of 40 oc
6
5
4
3
2
1
0
C.O.P


III. STEPS FOR CONVERTING R-12
TO R-134A REFRIGERATOR
C.O.P
fig 5.Experimental Set-up
-35 -30 -25 -20 -15 -10 -5
Temperature in oC
R-12
R-134a
0
fig.7 Variation of C.O.P with evaporator temp.at
condenser temperature of 40oc
From the fig.7 It is observed that the
coefficient of performance of the refrigeration
system is increasing almost linearly as the
Evaporator Temperature is increased when the
refrigerant used was R-12. The shape of the graph is
almost similar when the results were plotted using R134a as the refrigerant however it is observed that
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4. K. Nagalakshmi et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.638-643
www.ijera.com
the values of coefficient of performance are slightly
higher in case of refrigerants R-12. But refrigerant
are R-134a may be preferred because of the zero
value of the ozone depletion potential
Variation of Coefficient of performance with
evoparator temperature at condensor
temperature of 50 oc
-35 -30 -25 -20 -15 -10 -5
Temperature in
R-12
R-134a
0
oC
fig.8 Variation of C.O.P with evaporator temp.at
condenser temperature of 50oc
From fig8 It is observed that the coefficient
of performance of the refrigeration system is
increasing almost linearly as the Evaporator
Temperature is increased when the refrigerant used
was R-12. The shape of the graph is almost similar
when the results were plotted using R-134a as the
refrigerant however it is observed that the values of
coefficient of performance are slightly higher in case
of refrigerants R-12. But refrigerant are R-134a may
be preferred because of the zero value of the ozone
depletion potential
fig.9 Variation of Compressor Exit Temperature with
evaporator temp.at condenser temperature of 30oc
From fig.9 it is observed that the
compressor exit Temperatures keeping the
Condenser Temperature constant at 30ºC the
Evaporator Temperature is varied from -30ºC to 10ºC at intervals of 10ºC it is absorbed that from the
graph the compressor Temperature as the Evaporator
Temperature is increased from -10ºC to -30 ºC . In
case of R-134a the shape of the graph is similar in
case R-12.
fig.10 Variation of Compressor Exit Temperature
with evaporator temp.at condenser temperature of
40oc
From fig.10 it is observed that the
compressor exit Temperatures keeping the
Condenser Temperature constant at 40ºC the
Evaporator Temperature is varied from -30ºC to 10ºC at intervals of -10ºC it is absorbed that from the
graph the difference in the Compressor exit
temperature between R-12 & R-134a is more at an
Evaporator Temperature of -30 and is relatively less
when the Evaporator Temperature is -10ºC .
fig.11 Variation of Compressor Exit Temperature
with evaporator temp.at condenser temperature of
30oc
From fig.11 it is observed that the
compressor exit Temperatures keeping the
Condenser Temperature constant at 50ºC the
Evaporator Temperature is varied from -30ºC to 10ºC at intervals of -10ºC it is absorbed that from the
graph the difference in the Compressor exit
temperature between R-12 & R-134a is more at an
Evaporator Temperature of -30ºC and is relatively
less when the Evaporator Temperature is -10ºC
Specific volume
C.O.P
6
5
4
3
2
1
0
0.25
0.2
0.15
0.1
0.05
0
-40
-30
-20
-10
Evaporator temperature
R-12
R-134a
0
fig.12 Variation of specific volume with evaporator
temperature
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5. K. Nagalakshmi et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.638-643
According to the graph fig.12 the specific
volume is plotted against Evaporator Temperature it
is observed that the difference in specific volume
between R-12 & R-134a is less at an evaporator
Temperature of -30ºC and is relatively less when the
Evaporator Temperature is -10ºC .
From the graphs, we know that Coefficient
of Performance for R-12 refrigerant is slightly
greater than that of R-134a refrigerant. Even though
the C.O.P for R-12 refrigerant is slightly greater than
that of R-134a refrigerant, we prefer to use R-134a
refrigerant because its Ozone Depletion Potential
value is zero. Also, the replacement of CFCs with
HFCs provides more efficient refrigeration and does
not act as greenhouse gas and the less electricity is
needed for refrigeration.
V. CONCLUSION
It has been observed that the refrigerator
test rig is very much suitable for educational
purposes. In order to know working of VCR system
practically and also for knowing the pressure and
temperatures at various points of the cycle. These
results will help for modifications and for new
designs. It has been seen from the results and graphs
that COP of R12 is little greater than COP of R134a.
Even though COP of R12 is grater than R134a it
must be replaced withR134a because of following
reasons.
 R134a refrigerant is non-toxic and does not flare
up within the whole range of operational
temperatures.
 Ozone depletion potential ODP=0, global
warming potential GWP=0.25 and Estimated
Atmospheric life EAL=16.
 In Middle temperature refrigeration facilities
and air conditioning systems, refrigerating factor
of R134a is equal to the factor for R12 or higher
than that.
 In high temperature refrigeration facilities,
specific cold-productivity when operating on
R134a is also a bit higher than that of R12.
 Increasing of dehumidifying ability of filter
dehydrators due to high hygroscopic property of
R134a system-synthetic oil.
 Improvement of widely used all over the world
as a main substitute of R12 for refrigeration
equipment operating within middle-temperature
range. It is used in automobile air-conditioners,
domestic refrigerators, commercial refrigeration
middle-temperature
equipment,
industrial
facilities, air-conditioning systems in building
and industrial areas, as well as on refrigeration
transport.
 As R134a molecule has smaller size than R12
molecule which makes danger of leakage, this
can be avoided by using suitable materials, in
particular, with pads, made of such materials as
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“Buna-N”, “Khailaon”, “Neopren”, “Nordel
which are more compatible with R134a.
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6. K. Nagalakshmi et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.638-643
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